Low-Cost, High-Performance Composite Bipolar Plate

ABSTRACT

This invention describes a low-cost, lightweight, high-performance composite bipolar plate for fuel cell applications. The composite bipolar plate can be produced using stamped or pressed into the final form including flow channels and other structures prior to curing.

TECHNICAL FIELD OF THE INVENTION

The present invention relates in general to the field of low-cost, high-performance composites.

BACKGROUND OF THE INVENTION

Without limiting the scope of the invention, its background is described in connection with compound conductive materials.

Bipolar plates are an important key component of fuel cells primarily because of their ability to simultaneously provide a thermally and electrically conductive plate that also distributes and separates gases. Significant effort is aimed at reducing the weight and cost of bipolar plates for fuel cell applications. In the present investigation, efforts were made to develop composite bipolar plates by using methods and materials that allow compression stamping/pressing processes to achieve performance and cost goals. Today, most bipolar plates are composed entirely of graphite while progress is being made to one-day use lightweight composite bipolar plates made of graphite and a polymer filler. Thus far, graphite has been an ideal candidate for composing bipolar plates because of its mechanical, chemical, thermal, gas barrier, electrical, flame retardant and other properties.

Graphite is commonly used to enhance strength, electrical, and thermal conductivity of a composite material. Graphite has been used as a component in a wide number of composite materials including resins, epoxies, and polymers. Composite plates can be prepared by using different reinforcing fillers such as natural graphite, synthetic graphite, carbon black, or carbon fibers with phenolic resin as a polymer matrix precursor in its liquid and powder form. The composite plates prepared with appropriate proportion of components were characterized for physical and mechanical properties. It is found that by changing the component amounts for composite bipolar plates, improvements can be achieved that increase performance and decrease cost compared to that of pure graphite bipolar plates.

SUMMARY OF THE INVENTION

The method herein enables the dispersion/compounding of graphite, carbon black, graphene oxide or any additive with a polymeric component that can be extruded, stamped, or otherwise mass-produced into a bipolar plate. The particles of the one material are coated with the material of another conductive component or multiple conductive components using a milling process. The coated surface of the material creates conductive connective pathways through the volume of the final composite structure. By controlling the ratio of the components, one can achieve low density, high electrical conductivity, and surface hardness required for mass process by extrusion stamping or other mass manufacturing process.

In one embodiment, the present invention includes a method of making a conductive, composite bipolar plate made of coated particles for making a composite material that enhances a property of the composite material, comprising: providing a powdered component called a powdered host particle; providing a second powdered component called a conductive additive that comprises a softening or melting temperature higher than the melting point of the powdered host particle; inputting said powdered host particle and said conductive additive into a ball mill; and ball milling said powdered host and said conductive additive for a milling time to sufficiently mix but not melt the powdered host particle into a conductive host-additive particle. In one aspect, the powdered host particle is a powder from a resin of polymethylpentene. In one aspect, the conductive additive is comprised of graphite, graphene oxide, carbon nanotubes, or carbon nanowires. In one aspect, the conductive host-additive particle is formed into a bipolar plate assembly for a PEM fuel cell, and the bipolar plate comprises a formable resin with one or more conductive materials. In one aspect, the conductive host-additive particle is formed into a bipolar plate assembly for a PEM fuel cell that comprises the bipolar plate having a plurality of formed serpentine flow field on a first side of said bipolar plate and an interdigitated flow field on a second side of said bipolar plate, a plate margin having a first header aperture formed therethrough, a first port formed therethrough between said first header aperture and said serpentine flow field, a second header aperture formed therethrough, and a second port formed therethrough between said second header aperture and said interdigitated flow field. In one aspect, the conductive host-additive particle is formed into a bipolar plate assembly for a PEM fuel cell that comprises a first seal disposed on said second side of said bipolar plate and having a first passageway formed therein to define a first fluid transmission path between said first header and a second passageway formed therein to define a second fluid transmission path between said second port and said interdigitated flow field. In one aspect, the conductive host-additive particle is formed into a bipolar plate assembly for a PEM fuel cell comprises a second seal disposed on said first side of said bipolar plate and having a third passageway formed therein to define a third fluid communication path from said second header to said second port and a fourth passageway formed therein to define a fourth fluid communication path from said first port to said serpentine flow field. In one aspect, the powdered host particle is a powder from any resin of a particle size greater than 5 μm. In one aspect, the powdered host particle is a powder from a resin of polymethylpentene. In one aspect, the conductive additive is comprised of graphite, graphene oxide, carbon nanotubes or carbon nanowires or any combination formed in situ in the ball mill prior to the addition of the powdered host particle.

Another embodiment of the present invention includes a method of making a conductive composite particle or material, comprising: providing a powdered host particle; providing a conductive additive with a softening or melting temperature higher than the melting point of the powdered host particle; mixing the powdered host particle and the powdered additive in a ball mill; and milling the powdered host and the powdered additive for a time sufficient to mix but not melt the powdered host particle to form an electrically conductive host-additive blend. In one aspect, the powdered host particle is a powder from a resin of polymethylpentene. In another aspect, the electrically conductive host-additive blend has at least one of the following properties: a bulk density less than 1.75 g/cm³, an electrical conductivity greater than 250 S/cm, or a Rockwell hardness>80. In another aspect, the method further comprises the step of extruding, stamping, or otherwise mass-producing the electrically conductive host-additive blend into a bipolar plate. In another aspect, the bipolar plate is adapted for use in a PEM fuel cell, wherein the bipolar plate further comprises a formable resin with one or more conductive additives. In another aspect, the method further comprises the step of assembling the bipolar plate into a PEM fuel cell that comprises the bipolar plate having a plurality of formed serpentine flow field on a first side of said bipolar plate and an interdigitated flow field on a second side of said bipolar plate, a plate margin having a first header aperture formed therethrough, a first port formed therethrough between said first header aperture and said serpentine flow field, a second header aperture formed therethrough, and a second port formed therethrough between said second header aperture and said interdigitated flow field. In another aspect, the method further comprises the step of assembling the bipolar plate into a PEM fuel cell comprises a first seal disposed on said second side of said bipolar plate and having a first passageway formed therein to define a first fluid transmission path between said first header and a second passageway formed therein to define a second fluid transmission path between said second port and said interdigitated flow field. In another aspect, the method further comprises the step of assembling the bipolar plate into a PEM fuel cell comprises a second seal disposed on said first side of said bipolar plate and having a third passageway formed therein to define a third fluid communication path from said second header to said second port and a fourth passageway formed therein to define a fourth fluid communication path from said first port to said serpentine flow field. In another aspect, the powdered host particle is a powder from any resin of a particle size greater than 5 μm. In another aspect, the conductive additive is comprised of graphite, graphene oxide, carbon nanotubes, carbon nanowires or any combination.

DETAILED DESCRIPTION OF THE INVENTION

While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are illustrative of ways to make and use the invention and do not delimit the scope of the invention.

As used herein, the term “graphene” refers to a polycyclic hexagonal lattice with carbon atoms covalently bonded to each other. The covalently bonded carbon atoms can form a six-member ring as a repeating unit, and may also include at least one of a five-member ring and a seven-member ring. Multiple graphene layers are referred to in the art as graphite. Thus, graphene may be a single layer, or also may comprise multiple layers of graphene that are stacked on other layers of graphene yielding graphene oxide. Generally, graphene oxide can have a maximum thickness of about 100 nanometers (nm), specifically about 0.5 nm to about 90 nm.

As used herein, the term “graphene oxide flake” refers to a crystalline or “flake” form of graphene oxide that has been oxidized and includes many graphene sheets oxidized and stacked together and can have oxidation levels ranging from 0.01% to 25% by weight in ultra pure water. The flakes are preferably substantially flat.

As used herein, the term “PEM fuel cell” refers to a proton exchange membrane fuel cell, but also referred to as a polymer electrolyte membrane (PEM) fuel cell that converts, e.g., hydrogen and ambient air into water and an electrical current. The present invention finds particular uses in PEM fuel cells.

Graphite, graphene oxide, carbon nano tubes/fiber, and carbon black are collectively known as conductive components. Undoped TPX® Polymethylpentene (PMP) characteristics include electrical insulating properties and strong hydrolysis resistance (TPX® is a registered trademark to Mitsui Chemical). The TPX particles can be subjected to mechanochemical processing in what is generically referred to as a “ball mill.” The TPX has a particle size greater than or equal to 2 μm. When grinding in the ball mill, the balls (media) in their random movement are rolling against each other and the container, exerting shearing forces on the carbon black and the TPX particles. The resulting TPX particles can be coated on the exterior and have not been melted nor has the particle's size been reduced by more than 20% due to the milling process.

A useful and simple equation describing the grinding momentum is m×v (mass×velocity), which enables a calculation of how the attrition mill fits into the family of mills. For example, a 2-liter ball mill uses 6 lbs (or 2600 stainless steel balls) of 0.25″ diameter stainless steel balls weighing 1 g each. Milling or mixing can be accomplished in a closed chamber for 10 to 100 minutes at 1,000 RPM or less to coat the host particles. The other mills, such as sand, bead, and horizontal, use smaller media from 0.3 mm to 2 mm, but run at a very high rpm (roughly 100-1000). High-speed dispersers with no media run at an even faster rpm (1000-4000). An attrition mill directly agitates the media to achieve grinding.

For efficient fine grinding, both impact action and shearing force are generally required. The grinding media's random movement and spinning at different rotational energies exert shearing forces and impact forces on the carbon black and host particles. The milling/mixing time may range from 5 to 60 minutes. The combination of milling/mixing speed, media size and milling/mixing time enables the production of a host particle covered with conductive additives. The conductive composition of the composite can vary relative to each other but we have found a ratio of “77:3:10” (graphite:GO:TPX) exhibits the outstanding properties. By controlling the ratio of components, unique properties can be achieved such as a bulk density less than 1.75 g/cm³, electrical conductivity greater than 250 S/cm, and Rockwell hardness>80.

Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed, that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

It will be understood that particular embodiments described herein are shown by way of illustration and not as limitations of the invention. The principal features of this invention can be employed in various embodiments without departing from the scope of the invention. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this invention and are covered by the claims.

All publications and patent applications mentioned in the specification are indicative of the level of skill of those skilled in the art to which this invention pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.

The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims and/or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” The use of the term “or” in the claims is used to mean “and/or” unless explicitly indicated to refer to alternatives only or the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and “and/or.” Throughout this application, the term “about” is used to indicate that a value includes the inherent variation of error for the device, the method being employed to determine the value, or the variation that exists among the study subjects.

As used in this specification and claim(s), the words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

The term “or combinations thereof” as used herein refers to all permutations and combinations of the listed items preceding the term. For example, “A, B, C, or combinations thereof” is intended to include at least one of: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB. Continuing with this example, expressly included are combinations that contain repeats of one or more item or term, such as BB, AAA, AB, BBC, AAABCCCC, CBBAAA, CABABB, and so forth. The skilled artisan will understand that typically there is no limit on the number of items or terms in any combination, unless otherwise apparent from the context. In certain embodiments, the present invention may also include methods and compositions in which the transition phrase “consisting essentially of” or “consisting of” may also be used.

As used herein, words of approximation such as, without limitation, “about”, “substantial” or “substantially” refers to a condition that when so modified is understood to not necessarily be absolute or perfect but would be considered close enough to those of ordinary skill in the art to warrant designating the condition as being present. The extent to which the description may vary will depend on how great a change can be instituted and still have one of ordinary skilled in the art recognize the modified feature as still having the required characteristics and capabilities of the unmodified feature. In general, but subject to the preceding discussion, a numerical value herein that is modified by a word of approximation such as “about” may vary from the stated value by at least ±1, 2, 3, 4, 5, 6, 7, 10, 12 or 15%.

All of the compositions and/or methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions and/or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the invention as defined by the appended claims. 

What is claimed is:
 1. A method of making a conductive, composite bipolar plate made of coated particles for making a composite material that enhances a property of the composite material, comprising: providing a powdered component called a powdered host particle; providing a second powdered component called a conductive additive that comprises a softening or melting temperature higher than the melting point of the powdered host particle; inputting said powdered host particle and said conductive additive into a ball mill; and ball milling said powdered host and said conductive additive for a milling time to sufficiently mix but not melt the powdered host particle into a conductive host-additive particle.
 2. The method of claim 1, wherein the powdered host particle is a powder from a resin of polymethylpentene.
 3. The method of claim 1, wherein the conductive additive is comprised of graphite, graphene oxide, carbon nanotubes, or carbon nanowires.
 4. The method of claim 1, wherein the conductive host-additive particle is formed into a bipolar plate assembly for a PEM fuel cell, and the bipolar plate comprises a formable resin with one or more conductive materials.
 5. The method of claim 1, wherein the conductive host-additive particle is formed into a bipolar plate assembly for a PEM fuel cell that comprises the bipolar plate having a plurality of formed serpentine flow field on a first side of said bipolar plate and an interdigitated flow field on a second side of said bipolar plate, a plate margin having a first header aperture formed therethrough, a first port formed therethrough between said first header aperture and said serpentine flow field, a second header aperture formed therethrough, and a second port formed therethrough between said second header aperture and said interdigitated flow field.
 6. The method of claim 1, wherein the conductive host-additive particle is formed into a bipolar plate assembly for a PEM fuel cell that comprises a first seal disposed on said second side of said bipolar plate and having a first passageway formed therein to define a first fluid transmission path between said first header and a second passageway formed therein to define a second fluid transmission path between said second port and said interdigitated flow field.
 7. The method of claim 1, wherein the conductive host-additive particle is formed into a bipolar plate assembly for a PEM fuel cell comprises a second seal disposed on said first side of said bipolar plate and having a third passageway formed therein to define a third fluid communication path from said second header to said second port and a fourth passageway formed therein to define a fourth fluid communication path from said first port to said serpentine flow field.
 8. The method of claim 4, wherein the powdered host particle is a powder from any resin of a particle size greater than 5 μm.
 9. The method of claim 4, wherein the powdered host particle is a powder from a resin of polymethylpentene.
 10. The method of claim 1, wherein the conductive additive is comprised of graphite, graphene oxide, carbon nanotubes or carbon nanowires or any combination formed in situ in the ball mill prior to the addition of the powdered host particle.
 11. A method of making a conductive composite particle or material, comprising: providing a powdered host particle; providing a conductive additive with a softening or melting temperature higher than the melting point of the powdered host particle; mixing the powdered host particle and the powdered additive in a ball mill; and milling the powdered host and the powdered additive for a time sufficient to mix but not melt the powdered host particle to form an electrically conductive host-additive blend.
 12. The method of claim 11, wherein the powdered host particle is a powder from a resin of polymethylpentene.
 13. The method of claim 11, wherein the electrically conductive host-additive blend has at least one of the following properties: a bulk density less than 1.75 g/cm³, an electrical conductivity greater than 250 S/cm, or a Rockwell hardness>80.
 14. The method of claim 11, further comprising the step of extruding, stamping, or otherwise mass-producing the electrically conductive host-additive blend into a bipolar plate.
 15. The method of claim 14, wherein the bipolar plate is adapted for use in a PEM fuel cell, wherein the bipolar plate further comprises a formable resin with one or more conductive additives.
 16. The method of claim 11, further comprising assembling the bipolar plate into a PEM fuel cell that comprises the bipolar plate having a plurality of formed serpentine flow field on a first side of said bipolar plate and an interdigitated flow field on a second side of said bipolar plate, a plate margin having a first header aperture formed therethrough, a first port formed therethrough between said first header aperture and said serpentine flow field, a second header aperture formed therethrough, and a second port formed therethrough between said second header aperture and said interdigitated flow field.
 17. The method of claim 11, further comprising assembling the bipolar plate into a PEM fuel cell comprises a first seal disposed on said second side of said bipolar plate and having a first passageway formed therein to define a first fluid transmission path between said first header and a second passageway formed therein to define a second fluid transmission path between said second port and said interdigitated flow field.
 18. The method of claim 11, further comprising assembling the bipolar plate into a PEM fuel cell comprises a second seal disposed on said first side of said bipolar plate and having a third passageway formed therein to define a third fluid communication path from said second header to said second port and a fourth passageway formed therein to define a fourth fluid communication path from said first port to said serpentine flow field.
 19. The method of claim 14, wherein the powdered host particle is a powder from any resin of a particle size greater than 5 μm.
 20. The method of claim 14, wherein the conductive additive is comprised of graphite, graphene oxide, carbon nanotubes, carbon nanowires or any combination. 